Multi-directional rolling abdominal exercise device with minimal slip

ABSTRACT

A small, lightweight portable multi-directional or omni-directional rolling abdominal exercise device includes an over-molded roller ball having an outer molded layer; a housing supporting the roller ball for multi-directional movement; bearing members within the housing allowing for the rotational mounting of the roller ball; and handles coupled to the housing allowing for the user to engage the device with at least one of hands, elbows, knees or feet. The over-molded roller ball includes a ball core formed of a first and second hemispherical core member and an outer molded layer which completely encapsulates the ball core forming the ground engaging surface of the roller ball and which is configured to minimize slip, wherein each of the first and second hemispherical core members include grooves configured to engage the outer molded layer and wherein the outer molded layer comprises one of TPE, TPR, TPU, Silicone, rubber and mixtures thereof.

RELATED APPLICATIONS

This application is a continuation of International Patent ApplicationSerial Number PCT/US17/16474 filed Feb. 3, 2017 and published Aug. 10,2017 as WIPO publication WO 2017-136701, and International PatentApplication Serial Number PCT/US17/16474 claims priority to U.S.provisional patent application Ser. Nos. 62/290,756 and 62/299,738 filedFebruary 3 and 25, respectively, 2016, and each invented by EdwinMichael Barney and Ryan Bookhamer, and each entitled “Multi-DirectionalRolling Abdominal Exercise Device with Minimal Slip” which aboveidentified publication and applications are each incorporated herein byreference in their entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to an abdominal and oblique exercisedevice, and more particularly to a small, lightweight portablemulti-directional rolling abdominal exercise device with minimal slip.

Background Information

The history of exercise equipment goes back several millennia. Althoughbody-weight, calisthenics and yoga-based exercises were practiced by theancient Egyptians, Chinese, Indians and other cultures, the ancientGreeks are often credited with developing the earliest forms of modernexercise equipment, specifically weight training equipment. According tolegend, Milo of Croton, an Olympic wrestler of 6^(th) century BC,trained by lifting and carrying a newborn calf and repeating the featdaily as it grew to maturity. One of the first documented, moreconventional, “free weights” used in athletic training were known as“halteres”, or hand-held weights with a hole for gripping, which wereused as early as the fifth century B.C. Early Grecian illustrations alsoshow the use of dumbbells, weight plates and plummets to train forphysical strength.

Modern exercise equipment has become ubiquitous and highly specialized.One area of specialization is equipment concentrating on exercising therectus abdominis muscles, the external oblique muscles, the internaloblique muscles, and the transverse abdominal muscles which is commonlyreferenced as abdominal and oblique exercise equipment. Within thisspecialization of abdominal and oblique exercise equipment, there is adefinitive sub-set of such equipment that configured to be gripped bythe user and rolled along the ground such as via a wheel or ball. Thepresent invention described herein is directed to a small, lightweightportable structure multi-directional rolling abdominal exercise devicewith minimal slip.

The prior art patent literature, some of which are discussed below ingreater detail, has disclosed a number of abdominal exercise deviceswhich are formed as a small, lightweight portable structure andconfigured to be gripped by the user and rolled along the ground.

U.S. Pat. No. 3,403,906 from over 50 years ago illustrates an “exerciserwith grippers on a roller mounting shaft” consisting of a wheel on anaxel with user grips on the axel on either side of the wheel.

U.S. Pat. No. 5,004,229 from over 25 years ago illustrates a “portableexercise device” consisting of a wheel on an axel with user footengaging grips on the axel on either side of the wheel.

U.S. Pat. No. 6,942,605 from over a decade ago illustrates “exerciseequipment” comprising hand, elbow, knee and feet attachments with eachsupporting a plurality of casters to allow the user to roll along theground for exercise.

U.S. Pat. No. 7,285,080 illustrates an “exercising device having acombination of ball and rod” comprising a ball mounted on an axel (therod) extending to either side which can serve as user grips.

U.S. Pat. No. 7,621,858, analogous to the present invention, illustratesan apparatus for exercise utilizing an omnidirectional roller.

U.S. Pat. No. 7,993,250 illustrates an exercising device comprising aninflated ball mounted on an axel extending to either side which canserve as user grips.

U.S. Pat. No. 8,550,965, analogous to the present invention, illustratesan apparatus for exercise utilizing an omnidirectional roller withhandles coupled thereto.

U.S. Patent Publication No. 2012-0252645, analogous to the presentinvention, illustrates an apparatus for exercise utilizing anomnidirectional roller with handles coupled thereto.

WIPO Publication No. 2013-052192, analogous to the present invention,illustrates an apparatus for exercise utilizing an omnidirectionalroller with handles coupled thereto.

U.S. Patent Publication No. 2015/0190672 discloses a transformableexercise device used for both stability and strength training, which inone variation created a rolling device with handles coupled thereto.

The above mentioned patents and published applications are incorporatedherein by reference, however the omni-directional roller devices of U.S.Pat. Nos. 7,621,858, 8,550,965, and U.S. Patent Publication Nos.2012-0252645 2015-0190672 (the roller device variation) and WO2013-052192 are more closely related to the present invention.

The present invention builds upon the inventor's earlier work in thisfield set forth in U.S. Pat. No. 8,353,808, which is incorporated hereinby reference and which discloses a multi-directional rolling abdominalexercise device comprising a housing from which opposing interconnectedends of an axle or yoke extend and a support ball that is capturedwithin and partially extends from the housing. The housing has a cavitydefining a partial sphere for receiving the support ball. A plurality ofstrips are attached to the surface of the cavity and include a pluralityof bearings captured within a bearing race. The strips are positionedupon the cavity surface so as to engage the support ball surface and toprovide free-rolling support of the housing on the support ball in anydirection when the exercise device is in use. Commercial examples of theexercise device of the inventor's '808 patent are available under theABDOMINATOR™ brand at www.ABDOMINATOR.net. The support ball must beconstructed to be strong enough to operate in its intended fashion andhave suitable ground engaging properties for the device. There is a needto improve upon the construction of the ground engaging ball design ofthe '808 patent.

With this background, there remains a need for improved ground engagingball structures for multidirectional exercise equipment such asdisclosed in U.S. Pat. Nos. 7,621,858, 8,353,808, and 8,550,965, andU.S. Patent Publication No. 2012-0252645.

SUMMARY OF THE INVENTION

The present invention addresses the deficiencies of the prior art andprovides a small, lightweight portable multi-directional rollingabdominal exercise device with minimal slip utilizing an over-moldedball.

The present invention, according to one embodiment, provides a small,lightweight portable multi-directional rolling abdominal exercise deviceincluding an over-molded roller ball having i) a ball core and ii) anouter molded layer which completely encapsulates the ball core formingthe ground engaging surface of the roller ball and configured tominimize slip; a housing supporting the roller ball formulti-directional movement; bearing members within the housing allowingfor the rotational mounting of the roller ball; and handles coupled tothe housing allowing for the user to engage the device with at least oneof hands, elbows, knees or feet.

The multi-directional rolling abdominal exercise device according to oneaspect of the invention may provide wherein the outer molded layercomprises one of TPE, TPR, TPU, Silicone, rubber and mixtures thereofand wherein the ball core of the over-molded roller ball is formed of afirst hemispherical core member and a second hemispherical core member.The multi-directional rolling abdominal exercise device according to oneaspect of the invention may provide wherein each of the first and secondhemispherical core members include longitudinal grooves configured toengage the outer molded layer. The multi-directional rolling abdominalexercise device according to the invention may provide wherein each ofthe first and second hemispherical core members include acircumferential channel spaced radially inward from the outer surface ofthe first and second hemispherical core members and which is filled withthe material of the over-molded layer providing secure engagement of theouter molded layer to the first and second hemispherical core members.

These and other advantages are described in the brief description of thepreferred embodiments in which like reference numeral represent likeelements throughout.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is perspective view of a small, lightweight portablemulti-directional rolling abdominal exercise device with minimal sliputilizing an over-molded ball according to one embodiment of the presentinvention with straps removed for clarity;

FIG. 1B is a side elevational view of the exercise device of FIG. 1A;

FIG. 1C is a top plan view of the exercise device of FIG. 1A;

FIG. 1D is a perspective view of the exercise device of FIG. 1A with thestraps shown;

FIG. 2 is a perspective view of an over-molded roller ball for use inthe exercise device of FIG. 1A;

FIG. 3 is a perspective view of a ball core of the over-molded rollerball of FIG. 2;

FIGS. 4A and B are perspective views of a first hemispherical coremember of the ball core of FIG. 3;

FIGS. 5A and B are perspective views of an over-molded firsthemispherical core member of FIGS. 4A and B;

FIGS. 6A and B are sectional views of the over-molded firsthemispherical core member of FIGS. 5A and B

FIGS. 7A and B are perspective views of a second hemispherical coremember of the ball core of FIG. 3;

FIGS. 8A and B are perspective views of an over-molded secondhemispherical core member of FIGS. 7A and B;

FIGS. 9A and B are sectional views of the over-molded secondhemispherical core member of FIGS. 8A and B;

FIG. 10A is a perspective view of the over-molded layer of the first orsecond hemispherical core member of FIGS. 4A and B or FIGS. 7A and B,with the associated hemispherical core member omitted;

FIG. 10B is a perspective view of the over-molded layer of FIG. 10A;

FIG. 11A-C are sectional views of the over-molded roller ball of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1A-D collectively illustrate a small, lightweight portablemulti-directional (or Omni-directional) rolling abdominal exercisedevice 10 with minimal slip utilizing an over-molded roller ball 100according to one embodiment of the present invention. Apart from theconstruction and associated properties of the roller ball 100 discussedin detail below, the specific details of the device 10 are found in U.S.Pat. No. 8,353,808 which is incorporated herein by reference.

In general the small, lightweight portable multi-directional rollingabdominal exercise device 10 includes a yoke or housing 12 supportingthe roller ball for Omni-directional or multi-directional movement.Bearing members 14 are provided to allow for the rotational mounting ofthe roller ball 100, with the bearing members 14 shown being an X shaped(in top or plan view) set of roller bearing raceways and associatedbearings as described in further detail in the '808 patent. The devicefurther includes handles 16, shown here in the form of gel grip and kneepad, and straps 18 (FIG. 1D), allowing for the user to engage the device10 with hand, elbows, knees or feet, depending upon the exercise.

FIG. 2 is a perspective view of an over-molded roller ball 100 for usein the exercise device 10 of FIGS. 1A-D and yields the minimal slippageaspects of the present invention. The critical aspects of the presentinvention relate to the construction and associated properties of theover-molded roller ball 100 which yield better ground engaging andtracking properties by minimizing slip. “Over-Molded” within the meaningof this application as referring to the roller ball 100 intends todefine the coating of the exterior ground engaging surfaces of the ball100 with an outer molded layer 110 and in this embodiment is configuredto minimize slippage of the ball 100 and the associated device 10 inuse. The resulting device 10 of the present invention is not limited tothe housing construction and associated arrangement of the '808 patentgenerally shown in FIGS. 1A-D, but could similarly be implemented in thegeneral configurations set forth in U.S. Pat. Nos. 7,621,858, and8,550,965, and in U.S. Patent Publication No. 2012-0252645, which areall incorporated herein by reference.

FIG. 3 is a perspective view of a ball core of the over-molded rollerball 100 of FIG. 2, and which ball core is formed of a first and secondhemispherical core member 114 and 112. The outer molded layer 110completely encapsulates the ball core formed by the first and secondhemispherical core members 114 and 112 as shown in the figures. Thefirst hemispherical core member 114 of the ball core of FIG. 3 is bestillustrated in FIGS. 4A and B, and the second hemispherical core member112 of the ball core of FIG. 3 is best illustrated in FIGS. 7A and B.

Each of the first and second hemispherical core members 114 and 112include longitudinal ribbing or grooves 116 which allow for betterfrictional engagement of the outer molded layer 110 to the first andsecond hemispherical core members 114 and 112 without slipping. Havingthese features 116 extend into the surface of the core members 112 and114 uses less material for the minimal thickness for the outer moldedlayer 110 then if the same features extended outwardly from the surface“into” the layer 110.

Additional grooves 116 could be added and they may be “latitudinal” orotherwise angled to form a crisscross pattern of locking features 116.Each of the first and second hemispherical core members 114 and 112include a circumferential channel 118 spaced radially inward from theouter surface of the first and second hemispherical core members 114 and112, shown best in FIGS. 6A and B and 9A and B. The circumferentialchannel 118 is filled with the material of the over-molded layer 110 andprovides secure engagement of the outer molded layer 110 to the firstand second hemispherical core members 114 and 112 in addition to thefilled grooves 16. Each of the first and second hemispherical coremembers 114 and 112 include a series of radial and circumferentialinternal rib elements 120 for support.

The first and second hemispherical core members 114 and 112 may beformed of any suitable material, such as Acrylonitrile butadiene styrene(ABS) (chemical formula (C₈H₈)_(x).(C₄H₆)_(y).(C₃H₃N)_(z)) orABS/Poly-Carbonate (PC) mix. ABS is a common thermoplastic polymerexhibiting desirable lightweight properties and well as desirable impactresistance and toughness. Additionally ABS can be easily injectionmolded.

The first and second hemispherical core members 114 and 112 may beformed as any size desired depending upon the minimal thickness of theouter molded layer 110 and the final desired size of the roller ball100. In the illustrated example the first and second hemispherical coremembers 114 and 112 have a diameter of about 4.8 inches, which togetherwith a minimal depth of 0.1 inches for the outer molded layer 110 yieldsa roller ball of 5 inches in diameter.

Each of the first and second hemispherical core members 114 and 112include a series of engagement elements (loops 122, post slots 124,hooks 126 and posts 128) which align and engage with correspondingengagement elements on the other core member 112 or 114 to lock the twotogether (with adhesive). The loops 122 align with engaging hooks 126and the post slots 122 align with posts 128. The first hemisphericalcore members 114 is shown with four post slots 124, four loops 122 andfour hooks 126, while the second hemispherical core members 112 is shownwith four posts 128, four hooks 126 and four loops 122 in correspondingpositions. FIG. 11A-C are sectional views of the over-molded roller ball100 of FIG. 2, illustrating the locking engagement of the engagementelements (loops 122, post slots 124, hooks 126 and posts 128). Glue onselected engagement elements (not shown) may also be used to hold thefirst and second hemispherical core members 114 and 112 together.

The number and arrangement of engagement elements may be altered asdesired and it is envisioned that one could design identical coremembers each with two post slots 124, four loops 122, four hooks 126,and two posts 128, in which the members are rotated 90 or 180 degrees toproperly align before connection.

The outer molded layer 110 is molded directly to each hemispherical coremember 114 and 112. FIGS. 5A and B are perspective views of theover-molded first hemispherical core member 114 with outer molded layer110, while FIGS. 8A and B are perspective views of the over-moldedsecond hemispherical core member 112 with outer molded layer 110. Aninjection point may be through the center of each hemispherical coremember 114 and 112 while venting provided on the flat surface adjacentthe channel 118. The outer molded layer 110 wraps around eachhemispherical core member 114 and 112 and fills the channel 118 andleaves a flat connection surface at the channel for abutting the outerlayer 110 of the adjacent member 112 or 114. The channel and grooves 116locks the outer molded layer 110 to the respective hemispherical coremember 114 and 112.

FIG. 10A is a perspective view of the over-molded layer 110 of the firstor second hemispherical core members 112 or 114, with the associatedhemispherical core member omitted. FIG. 10B is a sectional view of theover-molded layer 110 of FIG. 10A.

The minimal thickness of the over-molded layer 110 depends upon thefinal desired dimensions of the roller ball 100, however as noted abovea 0.1 inch depth for layer 110 for the 4.8 inch diameter members 112 and114 yields an effective 5 inch diameter roller ball 100. As shown in thefigures the thickness of the layer 110 at the channel 118, or grooves116 or the injection port will be thicker to accommodate and fill theseelements. The final diameter of the roller ball 100 may be any desiredsize as generally known in the art and discussed in the inventor's prior'808 patent, which is incorporated herein by reference.

The first and second hemispherical core members 114 and 112 are madefrom material desired to give the necessary strength to the roller ball100. However over-molded layer 110 is designed to minimize the slippageand improve the tracking of the roller ball on a variety of surfaces(e.g., hardwood, tile, carpet, concrete, etc.). A varieties of rubber orsoft plastics are suitable for the layer 110, such as TPE, TPR, TPU,Silicone, rubber and mixtures thereof.

TPE refers to thermoplastic elastomers, sometimes referred to asthermoplastic rubbers, and are a class of copolymers or a physical mixof polymers (usually a plastic and a rubber) which consist of materialswith both thermoplastic and elastomeric properties. Thermoplastics areeasy to use in injection molding applications. There are six genericclasses of commercial TPEs: Styrenic block copolymers (TPE-s),Thermoplastic olefins (TPE-o), Elastomeric alloys (TPE-v or TPV),Thermoplastic polyurethanes (TPU), Thermoplastic copolyester andThermoplastic polyamides

TPR specifically refers to thermoplastic rubber (which can sometimesoverlap with TPE). TPR compounds are often formulated usingStyrene-Butadiene-Styrene (SBS) or Styrene-Ethylene/Butylene-Styrene(SEBS) block co-polymers. TPR materials have many of the same propertiesas vulcanized rubbers, but can be molded and extruded using conventionalthermoplastic processing equipment

TPU refers to thermoplastic polyurethane and technically, this is asubset of TPE's consisting of linear segmented block copolymers composedof hard and soft segments.

Silicones are polymers that include any inert, synthetic compound madeup of repeating units of siloxane, which is a chain of alternatingsilicon atoms and oxygen atoms. Silicone rubber is an appropriatesilicone for the layer 110.

The preferred embodiments described above are illustrative of thepresent invention and not restrictive hereof. It will be obvious thatvarious changes may be made to the present invention without departingfrom the spirit and scope of the invention. The precise scope of thepresent invention is defined by the appended claims and equivalentsthereto.

What is claimed is:
 1. A small, lightweight portable multi-directionalrolling abdominal exercise device comprising: an over-molded roller ballhaving i) a ball core and ii) an outer molded layer which completelyencapsulates the ball core forming the ground engaging surface of theroller ball and configured to minimize slip; a housing supporting theroller ball for multi-directional movement; bearing members within thehousing allowing for the rotational mounting of the roller ball; andhandles coupled to the housing allowing for the user to engage thedevice with at least one of hands, elbows, knees or feet.
 2. Themulti-directional rolling abdominal exercise device according to claim 1wherein the ball core of the over-molded roller ball is formed of afirst hemispherical core member and a second hemispherical core member.3. The multi-directional rolling abdominal exercise device according toclaim 2 wherein each of the first and second hemispherical core membersinclude longitudinal grooves configured to engage the outer moldedlayer.
 4. The multi-directional rolling abdominal exercise deviceaccording to claim 2 wherein each of the first and second hemisphericalcore members include a circumferential channel spaced radially inwardfrom the outer surface of the first and second hemispherical coremembers and which is filled with the material of the over-molded layerproviding secure engagement of the outer molded layer to the first andsecond hemispherical core members.
 5. The multi-directional rollingabdominal exercise device according to claim 4 wherein each of the firstand second hemispherical core members include a series of radial andcircumferential internal rib elements for support.
 6. Themulti-directional rolling abdominal exercise device according to claim 5wherein each of the first and second hemispherical core members isformed of Acrylonitrile butadiene styrene (ABS) and wherein the outermolded layer comprises one of TPE, TPR, TPU, Silicone, rubber andmixtures thereof
 7. The multi-directional rolling abdominal exercisedevice according to claim 5 wherein each of the first and secondhemispherical core members include a series of engagement elements whichalign and engage with corresponding engagement elements on the othercore member to lock the two together.
 8. The multi-directional rollingabdominal exercise device according to claim 7 wherein the engagementelements include loops, hooks, post slots and posts.
 9. Themulti-directional rolling abdominal exercise device according to claim 8wherein loops align with engaging hooks and the post slots align withposts.
 10. The multi-directional rolling abdominal exercise deviceaccording to claim 9 further including glue on selected engagementelements.
 11. The multi-directional rolling abdominal exercise deviceaccording to claim 5, wherein the outer molded layer is molded directlyto each hemispherical core member.
 12. The multi-directional rollingabdominal exercise device according to claim 11 further including aninjection point through the center of each hemispherical core member.13. A small, lightweight portable omni-directional rolling abdominalexercise device comprising: an over-molded roller ball having i) a ballcore and ii) an outer molded layer which completely encapsulates theball core forming the ground engaging surface of the roller ball andconfigured to minimize slip, and wherein the outer molded layercomprises one of TPE, TPR, TPU, Silicone, rubber and mixtures thereof; ahousing supporting the roller ball for multi-directional movement;bearing members within the housing allowing for the rotational mountingof the roller ball; and handles coupled to the housing allowing for theuser to engage the device with at least one of hands, elbows, knees orfeet.
 14. The multi-directional rolling abdominal exercise deviceaccording to claim 13 wherein the ball core of the over-molded rollerball is formed of a first hemispherical core member and a secondhemispherical core member.
 15. The multi-directional rolling abdominalexercise device according to claim 14 wherein each of the first andsecond hemispherical core members include longitudinal groovesconfigured to engage the outer molded layer.
 16. A small, lightweightportable multi-directional rolling abdominal exercise device comprising:an over-molded roller ball having a ball core formed of a firsthemispherical core member and a second hemispherical core member and anouter molded layer which completely encapsulates the ball core formingthe ground engaging surface of the roller ball and configured tominimize slip, wherein each of the first and second hemispherical coremembers include at least one of i) longitudinal grooves configured toengage the outer molded layer and ii) a circumferential channel spacedradially inward from the outer surface of the first and secondhemispherical core members and which is filled with the material of theover-molded layer providing secure engagement of the outer molded layerto the first and second hemispherical core members; a housing supportingthe roller ball for multi-directional movement; bearing members withinthe housing allowing for the rotational mounting of the roller ball; andhandles coupled to the housing allowing for the user to engage thedevice with at least one of hands, elbows, knees or feet.
 17. Themulti-directional rolling abdominal exercise device according to claim16 wherein each of the first and second hemispherical core membersinclude a series of radial and circumferential internal rib elements forsupport.
 18. The multi-directional rolling abdominal exercise deviceaccording to claim 16 wherein each of the first and second hemisphericalcore members is formed of Acrylonitrile butadiene styrene (ABS), andwherein the outer molded layer comprises one of TPE, TPR, TPU, Silicone,rubber and mixtures thereof, and wherein the outer molded layer ismolded directly to each hemispherical core member, and further includingan injection point through the center of each hemispherical core member19. The multi-directional rolling abdominal exercise device according toclaim 18 wherein each of the first and second hemispherical core membersinclude a series of engagement elements which align and engage withcorresponding engagement elements on the other core member to lock thetwo together.
 20. The multi-directional rolling abdominal exercisedevice according to claim 19 wherein the engagement elements includeloops, hooks, post slots and posts.